putting square holes in thick plate?

[kindyr]

I have a project I'm working on and looking for ideas. I don't have a mill. and no one I know has a mill.

I have steel plates, 1'by1' by 1"thick. I picked them up and a junk yard. they currently have a 1" round hole in the center. What I need for the project is to increase the size of that hole to 1.5" and square to fit a piece of square tubing. Angle grinder doesn't dig deep enough. i used the drill press for corner holes, and tried for connecting holes, but they started to drift into the enceter hole already there.

any idea how to do this wih a basic selection of handyman tools?

I have files, but I really don't have any file that would make that a practical option except for cleaning up the hole when it gets near it's final size.

 

[krusty the clown]

1" thick with handyman tools? i like to do things myself but i know my limitations.........

time is money, i would check with a machine shop, it may be better to pay them than waste 2 days you could doing something else.

 

[JakeD]

Cutting torch?

 

[rsanter]

rent a plasma cutter

bob

 

[mrpowderkeg]

jig saw, and go slow... I ended up doing that when making a turbo flange for a car... drilled inside scribed lines and cut it out with a jig saw, lots of blades and time

This was on 1/2 inch plate

 

[MXtras]

I would either torch or plasma cut it or just drag it to a shop.

If you are intent on doing it yourself, you could drill 3/8" holes in the corners then either hacksaw or jigsaw between the holes. The tubing likely has a radius on the corners - match the drill size.

Scott

 

[mike944]

One of those handles that holds a hacksaw blade on only one end. they work like ****, but it sounds like you don't have a lot of other options.

Either that, or you should think about making friends with someone with a mill.........

 

[Tantara]

Cutting torch

Brad

 

[Bigrhamr]

If it has to be a DIY job a torch would be your best bet. Clamp a piece of flatbar or something in place to use for a guide, just offset it from the cut line 1/2 a torch tip width. Then clean up with a die grinder if need be.
Better yet just get on your local Craigslist and look under services for somebody local with a mill in their garage, they're everywhere.

 

[CraigFL]

How about a square drill?

metalworking.com/DropBox/watts_Bros_prices.pdf

Only $234 in Y2004 prices...

 

[rjspitz]

How about a square drill?

metalworking.com/DropBox/watts_Bros_prices.pdf

Only $234 in Y2004 prices...

Yup, square hole bits...

http://toolmonger.com/2006/11/30/tool-tech-square-drill-bits/

 

[DHS]

jig saw, and go slow... I ended up doing that when making a turbo flange for a car... drilled inside scribed lines and cut it out with a jig saw, lots of blades and time
This was on 1/2 inch plate

I think that is his best option also. It cut 1/2" a lot better than I expected. Good luck.

 

[rsanter]

how many do you need to do?
what radius can you tollerate on the corners?
I have a mill, you could ship them to me using the flat rate boxes...

bob

 

[grego]

Yup, square hole bits...

http://toolmonger.com/2006/11/30/tool-tech-square-drill-bits/

These are too cool!! A few more things on the list then I have seen it all!!

 

[crashbumper]

Drilling square holes (it's really possible!):

 

[nate379]

How precise does it need to be?

If it's "rough" I'd just torch cut it.

If it needs to be precise you'll need to go with a waterjet or CNC Plasma table. Would need a pretty big plasma to clean cut 1" though.

The square hole drilling is cool! I thought you guys were fawking with him until I clicked on the videos!

 

[kindyr]

thanks for the advice guys. it looks like we're going to try a torch. they don't have to be exact, but close enough that a welder can fill any gap between the inch plate and the square tubing going through.
Rsanter- that is an extremely generous offer and I wish I could take you up on the offer. however, each plate weights near 40 lbs and I'm hoping to get four plates welded this monday.

thank you guys for the advice

 

[StumpXJ]

I have a mill also and would do it for you. Two USPS flate rate boxes would allow you to ship all 4 plates pretty cheaply. If the torch doesnt work, let me know.

~James

 

[nate379]

Torch should be fine. As long as you don't have huge gaps it won't be an issue to weld.... huge I mean over an inch...

 

[sberry]

Yup, to weld not a problem, tolerance pretty much would be a moot issue.

 

[rsanter]

thanks for the advice guys. it looks like we're going to try a torch. they don't have to be exact, but close enough that a welder can fill any gap between the inch plate and the square tubing going through.
Rsanter- that is an extremely generous offer and I wish I could take you up on the offer. however, each plate weights near 40 lbs and I'm hoping to get four plates welded this monday.

thank you guys for the advice

no problem
as a comunity we need to stick together

my advice for using a torch to do it:
drill the corners and if you can drill one ot two holes on each side
use the torch to connect the dots

bob

 

[Major Ramifications]

Could you cut the square tubing and weld it to the plate rather than going through it?

A good jigsaw, some good blades ane some cutting oil or coolant is the route I would take. I have a friend with a water jet, so that would be an option for me. I think my Bosch jigsaw would handle the task without any problem, though.

 

[danski0224]

A nice jigsaw, like a Bosch, and some good blades will get this done in short order.

Good blades and a jigsaw with a lower blade guide will make some nice cuts. Let the blade do the work and the holes will turn out nice.

Two blades per hole should do it.

 

[MikeD74T]

If the corners are already drilled I think I could have one hole cut with a sawsall in the time it took to read this thread. Then a file for cleanup.
MikeD74T

 

[nissan_crawler]

If the corners are already drilled I think I could have one hole cut with a sawsall in the time it took to read this thread. Then a file for cleanup.
MikeD74T

Speaking of reading a thread, this was posted two months ago.

 

[Doozer75]

You need one of these.

DoAll 1612
Use a 1/4" blade. Thread the blade through the hole and use the blade welder.

--Doozer

 

[Bigger Hammer]

A person can do a lot with an OA torch and a die grinder. But if its for welding purposes, cut your bevels top and bottom with the torch and weld away.

 

[Todd.Brock]

im all for doing it youself but that seems like it may be money well spent for a machine shop. The guys who say a sawzall or jigsaw, will they really cut through an inch thick steel? It seems even the torch would be slow going at best.. i love me some sawzall at the junkyard for cutting off driveshafts and through cross members, but 1"???

 

[lilclay81]

i would use a cutting torch or good plasma cutter with a guide. That how i have cut thick metal